Fabrication of bonded structures

ABSTRACT

Bonding pressure is uniformly applied to the lay-up (70) of a bonded product (10) by the disposition of flexible, compressible, perforated sheet material (85) between the lay-up and a pair of molds (75 and 80) during the manufacture of the product by diffusion bonding.

The Government has rights in this invention pursuant to Contrast No. F33657-79-C-0504 awarded by the Department of the Air Force.

This application is a continuation of Ser. No. 814,421, filed Dec. 30, 1985, now abandoned.

TECHNICAL FIELD

This invention relates generally to the manufacture of bonded structures and particularly to enhancing the uniformity of the application of bonding pressure to such structures.

BACKGROUND ART

Methods of manufacture which involve the machining of an article from homogeneous material have, in large measure, given way to modern manufacturing techniques wherein an end product is produced by bonding a plurality of constituent components under conditions of elevated pressure and often, elevated temperature. By way of example, airfoils such as those employed in aircraft propellers are often manufactured from high strength composite constituents such as plies of fiberglass reinforced expoxy resin which are layed up and then bonded together within a mold having a cavity corresponding to the desired airfoil geometry. Recently, diffusion bonding of composites such as boron reinforced aluminum has received attention as an alternative to the machining of airfoils such as gas turbine engine fans, from high strength metals.

Those skilled in the art will recognize that the application of insufficient bonding pressure to portions of a composite lay-up in a diffusion bonding process, will result in weakened areas in the product produced thereby. Uniformity in bonding pressure is a function of conformity of the lay-up to a predetermined, nominal shape. Therefore, nonuniformity in the thicknesses of the composite constituents can lead to substantial nonconformity of the lay-up to such a nominal shape and nonuniformity in the application of bonding pressure to the lay-up. Thus, variations in the thicknesses of the constituent composite plies due to normal tolerances in the manufacture thereof, can result in the application of insufficient bonding pressure to the lay-up and, therefore, inadequate structural integrity of the end product. Accordingly, in manufacturing processes such as the diffusion bonding of metallic composites wherein an assembly of constituents are bonded together within a mold under conditions of elevated pressure, a mechanism for evenly distributing bonding pressure in the face of deviation in constituent dimensions from nominal dimensions, is required.

DISCLOSURE OF INVENTION

It is therefore, among the objects of the present invention to provide an improved manufacturing technique wherein an assembly of constituents exhibiting geometrical variations from nominal, is bonded under conditions of uniformly distributed bonding pressures for the enhancement of the structural integrity of an end product.

In accordance with the present invention, bonding pressures are evenly distributed over a lay-up of constituents such as composite plies by the disposition of a flexible, compressible perforated sheet material between a mold and the lay-up. Where sufficient bonding pressures exist, the material of the sheet compresses in thickness and expands into adjacent perforations thereof to provide a path for the application of bonding pressure to those portions of the lay-up which would otherwise receive insufficient bonding pressure due to deviation in constituent dimensions from nominal. In the preferred embodiment, the bonding method comprises diffusion bonding wherein layers of composites such as boron fiber reinforced aluminum are bonded to one another and the flexible, compressible perforated sheet material comprises a woven aluminum mesh. Those portions of the mesh where aluminum strands cross over one another are compressed and spread to adjacent areas of single strand thickness and into the mesh perforations to provide the paths for the distribution of bonding forces from the molds to the composite layers.

In an alternate embodiment of the present invention, the flexible, compressible perforated sheet material is disposed within the lay-up and becomes part of the end product.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a gas turbine engine fan blade manufactured in accordance with the present invention;

FIG. 2 is an enlarged fragmentary view of a portion of the blade of FIG. 1, portions thereof having been removed to illustrate details of the structure thereof;

FIG. 3 is an elevation of a pressure bonding process being performed in accordance with the present invention;

FIG. 4 is a fragmentary enlargement of a portion of FIG. 3;

FIG. 5 is a plan view of a woven wire mesh employed in the bonding process illustrated in FIGS. 3 and 4;

FIG. 6 is an edge view of the woven mesh illustrated in FIG. 5; and

FIG. 7 is a view similar to that of FIG. 2, but illustrating a alternate blade manufactured in accordance with the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION AND INDUSTRIAL APPLICABILITY THEREOF

Referring to FIG. 1, there is shown a gas turbine engine fan blade 10 mounted on a rotatable hub 15. Blade 10 is of the "spar-shell" variety, comprising a high strength spar 20 of titanium or the like having a dovetail root end 25 which fits within a mating slot in hub 15. Blade 10 also includes a composite shell 30 bonded to the spar and covered at the leading edge thereof with a sheath 35.

For purposes of economy of manufacture and to achieve high strength-to-weight ratios, shell 30 is formed from a plurality of high strength composite plies bonded to the spar by diffusion bonding techniques. Referring to FIG. 2, titanium spar 20 is disposed interiorly of shell 30, at the leading edge of a solid aluminum fill piece (shim) 40. Sheets of aluminum foil 45 overlie spar 20 along the major surfaces thereof and provide bonding material for a diffusion bond between the spar and adjacent layers 50 of composite material. The composite layers comprise thin sheets of an aluminum matrix having strands of boron embedded therein. As illustrated, the composite sheets may be layed up over the spar and fill piece 40 with any suitable relative angular orientation of the boron fibers. While FIG. 2 illustrates only four layers of composite covering the spar, it will be understood that any suitable number of layers may be employed. An aluminum bonding foil sheet 55 disposed adjacent to the trailing edge of fill piece 40, provides bonding material for the diffusion bond between the composite plies and titanium outer skin layers 60 at the trailing edge of the blade. Aluminum bonding foil sheets 65 which overlie composite 50, provide material for the bonding of outer skin layers 60 to the underlying composite sheets.

Blade 10 is manufactured by first forming a subassembly of spar 20 and fill piece 40, the mating shapes of these components being formed by any suitable means such as machining. The spar and fill piece are then diffusion bonded together under conditions of elevated pressure and temperature. The spar-fill piece subassembly is then layed up with the various layers of bonding foil, composite sheets and skin as described with respect to FIG. 2 to form a blade lay-up 70 which is then placed within mold halves 75 and 80. The various metallic and composite layers in lay-up 70 are then diffusion bonded within mold halves 75 and 80 under conditions of elevated temperature (960°-990° F.) and pressure (6000-9000 psi) to form the fan blade illustrated in FIG. 1.

As set forth hereinabove, to assure structural integrity of the blade, it is necessary that sufficient bonding pressure be evenly distributed over the entire lay-up. As further set forth hereinabove, dimensional variations in the thicknesses of the constituent plies can result in areas of the lay-up deviating in thickness from a nominal thickness. This in turn can result in failure of the thinner than nominal portions of the lay-up to receive adequate bonding pressure, whereby these portions are inadequately bonded in the end product.

To evenly distribute adequate bonding pressure over lay-up 70, as illustrated in FIGS. 3 and 4, flexible, compressible, perforated sheet material 85 is inserted between lay-up 70 and the mold halves prior to the actual diffusion bonding of the constituents. Thus, the diffusion bonding force is applied to lay-up 70 from mold halves 75 and 80 through the perforated sheet material. As illustrated in FIGS. 5 and 6, the sheet material may comprise a woven mesh of aluminum strands 90. In the preferred embodiment, with the various plies being formed from the noted materials, woven mesh 85 comprises AA6061, 0.014 inch diameter aluminum wires in a 22 by 22 wire per inch distribution. It will be seen that diffusion bonding pressure applied by mold halves 75 and 80 will first be exerted on the thicker than nominal areas of the lay-up, first deforming the wire crossovers (those portions of the mesh where adjacent strands cross one another). This results in compressive yielding (widening) of the crossovers into those areas of single strand thickness and eventually into the open (perforated) areas between the strands. Such strand yielding establishes continuous paths for the application of bonding force from the mold halves to any thinner than nominal portions of lay-up 70. This in turn increases the uniformity of the application of bonding pressure to the entire lay-up, thereby minimizing the risk of weakend areas therein.

Those skilled in the art will appreciate that a calibration of mesh porosity, versus mesh thickness, versus applied bonding pressure may be emperically established for purposes of substantiating the adequacy of bonding pressure applied to a lay-up formed from materials of specified thickness tolerance. In a somewhat similar vein, conformity of dies to a desired shape may be substantiated by use of mesh 85. In such case, a finished product of predetermined geometry would be compressed with the mesh disposed between the product and a pair of dies to be checked. Variations in mesh thickness and porosity under conditions of the application of a predetermined bonding force would indicate deviation of die shape from a desired product geometry.

Referring to FIG. 7, enhanced uniformity in the application of bonding pressure to the lay up may also be achieved by the disposition of the wire mesh within the blade itself. In this case, mesh 85 is substituted for the bonding foils beneath the titanium skin and at the trailing edge of aluminum fill piece 40. When so disposed, mesh 85 not only yields in the manner described hereinabove, to provide continuous force application paths from the mold halves to the lay-up, but also provides material for the bonding of the various constituents to one another in the manner of foils 55 and 65 which the mesh replaces within the finished blade.

While specific embodiments of the present invention have been described and illustrated, it will be understood that various modifications thereof may suggest themselves to those skilled in the art. For example, while the invention herein has been described within the context of the manufacture of a metallic composite fan blade, it will be understood that this invention has equal utility in the manufacture of any product by means of molding constituents of any composition with elevated pressures. Therefore, while an aluminum wire mesh has been disclosed, any of various other flexible, compressible, perforated sheet materials may be employed as is dictated by the nature of the constituents. Accordingly, it will be understood that the following claims cover all modifications which fall within the true spirit and scope of the invention herein. 

Having thus described the invention what is claimed is:
 1. In a method for manufacturing an article by the compression molding under conditions of elevated pressure, of a lay-up of constituents within a mold having an interior shape corresponding to the desired shape of said article, wherein said constituents are first inserted within said mold, the improvement characterized by:inserting within said mold, between said mold and said constituents, a flexible perforated sheet material which is softer than said mold; and bonding said constituents into said article by said compression molding of said lay-up while compressively deforming said sheet material in a manner in which select, solid portions of said sheet material locally expand into perforations thereof; uniformity of pressure distribution between said mold and constituents being enhanced by said localized expansion to reduce the size of perforations therein, thereby establishing continuous paths therethrough for the application of adequate bonding pressure to said lay-up, whereby weaknesses in the bonding of said constituents due to variations in molding pressure resulting from dimensional inconsistencies of said constituents, are minimized.
 2. The method of claim 1 characterized by said sheet material being disposed between said mold and said lay-up.
 3. The method of claim 1 characterized by said sheet material being disposed within said lay-up.
 4. The method of claim 3 characterized by said article comprising a fan blade, said constituents comprising composite sheets of high-strength filaments disposed in a metallic matrix, said lay-up of said component sheets being covered by a metallic skin and said sheet material comprising a woven fabric mesh formed from metallic strands, said mesh being disposed between said skin and an outermost one of said composite sheets.
 5. The method of claim 4 characterized by said woven fabric mesh being further disposed interiorly of said composite sheets.
 6. The method of claim 1 characterized by said perforated sheet material comprising a fabric mesh.
 7. The method of claim 6 characterized by said fabric mesh being woven.
 8. The method of claim 7 characterized by said compression molding comprising diffusion bonding under conditions of elevated temperature.
 9. The method of claim 8 characterized by said constituents comprising composite sheets of high strength filaments disposed in a matrix.
 10. The method of claim 9 characterized by said filaments comprising boron and said matrix and said woven fabric mesh being metallic.
 11. The method of claim 10 characterized by said matrix and woven fabric mesh comprising aluminum.
 12. A method for determining the conformance of mold tooling to an article of select surface geometry, said method being characterized by:inserting a sheet of flexible, compressible, perforated material between said mold tooling and said article; compressing said material between said article and said mold tooling while compressively deforming said sheet material in a manner in which select, solid portions of said sheet material locally expand into perforations thereof; and noting any areas of said perforated material which exhibit variations in thickness and porosity thereof subsequently to said compression; areas of reduced material thickness and porosity corresponding to, and being indicative of nonconformance between said article and said mold tooling. 